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On spec with maximum profit in milk powder processing

Gain tighter control of milk powder to meet specifications while making optimal use of materials and resources

Dairy powder production

 

Offering a long shelf-life and ease of transport, milk powder has become a popular global commodity in our increasingly complex food supply chains.

 

A growing market awaits for producers who can do milk powder processing while closely matching the strict quality specifications for international trade such as the Codex Alimentarius CXS 207-1999 Standard for milk powders and cream powder. In addition to matching specifications for key control parameters such as moisture and protein, the integrity of the product and sustainable production are of growing concern from milk producers to consumers.

 

With the ability to fine-tune the process, the tightly controlled arena of milk powder processing holds rewards through reduced waste and quality issues and optimal use of materials and resources. Protein, for instance, can be closely controlled in powder processing with lactose or permeate from an ultra-filtration process and by standardisation of incoming milk at the start of the production process. Likewise, moisture content of powder can be closely monitored during drying for quality and the most rational use of resource-intensive processes.

Insights add value

 

 

Dairy powder production process

Incoming milk

Standardise your fat and protein content for consistent products and maximum profit. Make on the spot checks on hygiene quality for optimal shelf-life and screen for accidental or deliberate adulteration of the milk supply.

In process

Control protein in the process and moisture in the drying step.

Final products

Analysis at the critical final stage of production helps you to limit liabilities and potentially damaging product recalls. Instead you can enjoy the peace of mind that comes from knowing your products meet specifications.

Standardise incoming milk closer to target levels with consistently accurate analysis

As protein is the highest priced milk powder component, the tight control afforded by standardisation at the start of milk powder processing can be a major boost to profitability. The ratio of fat and protein content is of interest with speed and accuracy being key in handling variations in supply. What’s more, the effect of reducing the variation in fat and protein in milk is magnified in the process. For instance, a reduction in variation of 0.03 % in the milk will lead to a ten-fold reduction of 0,3 % in the powder for fat and protein content.

 

MilkoScan FT3 standarisation graph

 

MilkoScan™ FT3 has an automatic performance check that runs every two hours. This eliminates instrument drift and ensures stable results over time, making it the perfect solution for milk standardisation where consistent analytical performance is critical and especially where fleets of instruments are involved.

 

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Hygienic quality for yield and specifications

 

In the finely tuned milk powder process, bacteria and somatic cell count of incoming milk can have a profound effect on efficiency and yield. In particular, spore-forming bacteria have become an increasing area of concern for dairy powder processors because of stringent customer specifications. A quick and reliable test to ensure low counts going into the process makes sense for any production.

 

New analytical technology helps you to handle incoming milk for optimal results downstream. Advances in analytical technology for checking the hygiene quality of milk now make it possible to test milk within minutes so that a result is available before it is unloaded from the delivery truck and mixed with the rest of the supply.

 

The innovation involves equipment using so-called flow cytometry technology for counting bacteria and somatic cells in the raw milk. The analyser incubates a sample of milk and then uses a laser to count individual bacteria and somatic cells that determine the hygiene quality and subsequent suitability for processing. Learn more about the BacSomatic™ analyser.

Senior Technical Manager of Müller Milk and Ingredients explains the value of rapid raw milk hygiene testing.

Screening for adulterants as part of existing control

 

The risk of contamination in milk powder processing is always top-of-mind throughout the tightly-controlled milk powder production and supply chain. The problem is greater in developing milk industries, but even the most well-established milk delivery and processing systems can suffer from accidental contamination, for example, with cleaning fluids used to clean tanker trucks. A smart line of defense is that the same analytical equipment used for milk standardisation can also perform checks for possible adulteration at the same time.

 

Exploiting powerful FTIR technology, the MilkoScan™ FT3 provides the most precise and widest scope of adulteration screening capabilities in the industry. You can check for deliberate or accidental adulteration while performing normal quality control tests.

In-line process measurements for manual or automatic adjustment of processes

Precise and continuous analysis during milk processing can make a big difference to yield and profit while always remaining within specifications.

 

The latest benchtop analysers based on near infrared (NIR) technology are proven to deliver highly accurate test data that is valuable for control of milk powder processing. However, the intervals between tests mean that fluctuations in key control parameters can go unnoticed. Accordingly, a safety margin for meeting protein and moisture targets must be applied.

 

Continuous measurements with in-line NIR analysis directly in the process pipe keeps you ahead of the game by spotting smaller variations in protein and moisture and allowing prompt adjustment of the process. The process can be pushed ever-closer to targets while staying within strict specifications. At the same time, the highly stable benchtop NIR instruments can be used to regularly monitor the performance of the in-line analysis instruments.

 

For instance, measuring protein just after the UF filter allows adjustment of lactose or permeate for better results downstream. A dairy plant producing 10,000 tonnes of milk powder per year can decrease the protein solids-non-fat ratio by 0.6% and save up to €250.000 per year. Likewise, tighter control of moisture leads to another profit gain in the energy-intensive drying process. A powder production with an output of 70,000 tonnes per year moves moisture closer to target by 0.1% leading to a yield increase worth €147,000.

 

 

ProFoss 2 Powder Probe

 

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Effective finished product analysis

 

Analysis at the critical final stage of production helps you to limit liabilities and potentially damaging product recalls. Instead you can enjoy the peace of mind that comes from knowing your products meet specifications.

 

The majority of this testing can be performed using rapid routine analysis with NIR, but certified chemical analysis methods are also often required for validation of compliance with certain end-product criteria. For chemical analysis we can provide a complete range of solutions aimed at automating steps for speed and safety while minimising use of chemicals.

 

Dedicated industry solutions

 

For any industry player, from single plants to multi-national organisations analytical solutions can help you improve the consistency of consumer milk products while boosting your profit through razor-sharp control of the use of expensive milk components.

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With you in your daily work

 

Our integrated and remotely controlled support and optimization services ensure maximum value from all your FOSS solution wherever you are in the world. Beyond on-site maintenance, our service engineers and application specialists are always with you online. The team monitors performance status and secures that your connected analytical operations run smoothly. Our preventive maintenance warrants up-time and quality of data - day after day. Read more.

Thumbnail picture presenting MilkoScan FT3 on a blue background

MilkoScan™ FT3

The MilkoScan™ FT3 offers a new, intelligent approach to dairy analysis including the power to test a wide variety of liquid and semi-solid dairy products with exceptional uptime and unprecedented consistency of results. Learn more

ProFoss™ 2 Dairy

ProFoss™ 2 Dairy is an in-line dairy analyser for monitoring milk concentrate and dairy powder.


This dairy analyser gives you continuous analysis of protein and moisture after the dryer in your final dairy powder.

 

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ProFoss 2 Butter
NIRS DS3 Product Picture

NIRS™ DS2500 Dairy Powder Analyser

The NIRS™ DS2500 Dairy Powder Analyser helps you to improve yield in your dairy powder production. Designed for use in the laboratory or at the production line, the NIRS™ DS2500 is a practical quality control tool ideal for routine production control and monitoring of final product quality. Read more

Are you ready to explore the value of rapid dairy powder analysis in your production?

Get in touch with our specialists to learn how other powder producers have optimised their production with our solutions. Let's talk